Globally, environmental conservation is a top priority. Industry, on the whole, is generally considered a top threat to resources and climate change. Recent statistics bear out the concern. Around 38% of overall global energy consumption and 24% of total CO2 emissions are attributed to industrial production.1 Continued industrial expansion suggests the percentages will continue to rise exponentially, as will energy prices since general worldwide demand for energy is predicted to nearly double by 2035.
Tissue products constantly evolve to meet market demands and consumer preferences. Tissue converters must do likewise to remain relevant to their customers and ahead of the competition. This presents a challenge when it comes to equipment: purchase new or modify existing?
A tissue converting operation doesn’t have to be completely destroyed to be debilitated by fire. Learn more about how new technology and tools can help keep your facility, as well as your workers, and equipment, safe from the threat of fire in this brief video.
At one time or another, tissue converters are faced with purchasing or replacing equipment. It is a substantial investment that warrants careful consideration about how to spend capital. There is always the option to buy new, but at times it is simply a better business decision to acquire pre-owned machines.
With dangerous and disruptive log saw blade changeovers to consider, how do tissue converters keep their workers safe and their lines moving? The solution lies in the Blade Change Technical Improvement Program (TIP) — advanced automation technology that decreases human-machine interaction and significantly increases worker safety. Learn more in this video:
Manual tasks within the unwinding process put many tissue converters at a disadvantage. Operators are responsible for the preparation and transition of parent reels between paper machines and the converting line, which is physically demanding and often time-consuming. Further, these functions increase the likelihood of damage to the tissue and greatly jeopardize operator safety — all substantial risks for tissue converters.
With the advent of Industry 4.0 and smart technologies, solutions to these challenges are now available and Fabio Perini’s new Moonlight unwinder virtually eliminates off-line human intervention during unwinding through forward-thinking automation:
Fabio Perini North America has always focused on adding value as a full-service partner for tissue converters. So, when the opportunity arose to eliminate waste, improve quality and deepen customer relationships through the implementation of Lean practices, the choice was easy. Learn more in this video.
As tissue converting equipment advances, a customer’s knowledge may not keep pace, which can lead to a disconnect when trying to solve problems or improve efficiencies. Fortunately, skilled technicians are available via augmented reality to help troubleshoot problems digitally. Learn more in this video.
Like any industry predicated on production, tissue manufacturing and converting presents a certain amount of peril to workers. The amount of equipment and humans on a production floor alone can make for hazardous situations, not to mention the often heavy, sharp, and quickly moving parts within that equipment that workers must be cognizant of at all times to prevent injury if safe practices and machine safety procedures are not being followed or used.
A measure of the difference between the ideal — the cost of doing everything perfectly the first time every time — and the actual costs associated with the reality of errors and inefficiencies in processes, the Cost of Poor Quality (COPQ) can erode as much as 15-20% in sales revenue and up to 40% of total operational budgets for many organizations. If resolving quality issues isn’t addressed until somewhere in the cycle when the product transitions from planning to manufacturing to distribution, COPQ could further endanger profitability.